System of building construction



Dec. 15, 1959 E. A. MILLER SYSTEM OF BUILDING CONSTRUCTION 2 Sheets-Sheet 1 Filed Jan. 9, 1956 "56 2o 24 28 so 32 INVENTOR.

EDWARD A. MILLER BY 9 I6 ATTORNEYS 1 Dec. 15, 195.9 E. A. MILLER SYSTEM OF BUILDING CONSTRUCTION 2 Sheets-Sheet 2 Filed Jan. 9, 1956 neg.

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EDWARD AMILLER BY max,

ATTORNEYS United States Patent 2,916,909 SYSTEM OF BUILDING CONSTRUCTION Edward A. Miller, Grosse Pointe Park, Mich., assignor to Fenestra Incorporated, a corporation of Michigan Application January 9, 1956, Serial No. 558,042 9 Claims. (Cl. 72-66) ,building panels in. conjunction with filler form elements serve as a permanent form while the concrete is being poured and become a permanent part of the finished structure.

In the system of concrete building construction wherein metal building panels serve as a permanent form while the concrete is being poured and become a permanent part of the building, as disclosed in Miller et al. copending application Serial No. 507,594, filed May 11, 1955, downwardly open troughs of the panels provide recesses for lighting fixtures and for the installation of sound absorbing material. Open channels between the troughs of the panels are adapted to receive concrete to form reinforced joists for the concrete ceiling construction. It is desirable to vary the depth of the channels between the troughs, when the panels are used in different areas of the building structure, to provide joists that vary in depth and to be of a strength required to support loads that vary with the distances spanned by the joists in the different areas of the building.

It is an object of the present invention to provide metal building panels, having filler form elements, to be used as a mold or form for the floors or roofs and ceiling of building structures when pouring concrete to form a part of the floor or roof ceiling construction.

It is a further object of the present invention to provide filler form elements adapted to be used with metal building panels to allow a standard optimum size and weight of panel suitable to serve as a form when concrete is being poured and provide channels that can vary in depth to form concrete joists of a strength suitable for the distances spanned and the loads supported in the finished floor or roof ceiling construction.

It is a further object of the present invention to provide a filler form element that is non-load bearing in character and thus economical to manufacture and adapted to be used with metal building panels to allow a standard optimum size and Weight of panel suitable to serve as a form when concrete is being poured and provide channels of a greater height than that formed by the panels to form concrete joists of a depth and strength suitable for the distances spanned and the loads supported in the finished floor or roof ceiling construction.

Other objects and features of the invention will become apparent as the description proceeds, especially when taken in conjunction with the accompanying drawings, wherein:

Figure 1 is a perspective view, partly in section and partly broken away of the building system with the filler forms in place.

Figure 2 is an enlarged partial cross-section of the structure shown in Figure 1, taken through a plane running along the length of an acoustical type panel.

Figure 3 is an enlarged partial cross-section of the "ice structure shown in Figure 1, taken in a plane at right angles to the length of the panels.

Figure 4 is a partial cross-section similar to that of Figure 3 with the filler form being of a shorter height.

Figure 5 is a perspective view partly in section and partly broken away, with a gap left between two filler forms to form a cross beam in the building structure.

Referring now to the drawings, there is illustrated a floor-ceiling construction for use in a concrete building structure. The construction includes an acoustically treated panel 20, the panel including an elongated upwardly extending section 22 defining a downwardly open elongated trough, and a flat plate section 24 welded or otherwise permanently secured along flanges 26 to the section 22 and extending laterally therebeyond. The flat plate 24 of the acoustical panel is provided with a multiplicity of apertures 28 which permit sound waves to penetrate into the interior of the panel to be absorbed by a blanket 30 of suitable sound absorbing material such as glass fibers. The blanket is preferably spaced from the apertured portion of the plate 24 by a wire chair 32 so as to prevent the apertures 28 from being plugged. The ends of the panel are closed by suitable means such for example as the cap 34.

Associated with the acoustically treated panels are panels indicated at 40 adapted to accommodate and form a part of recessed lighting fixtures. The panels 40, like the panels 20, and as well illustrated in Figure 3, include an elongated upwardly extending section 42 forming a downwardly open elongated trough. Attached to the fluted sections 42 are elongated strips 44 and 46 the inner edges of which are spaced apart to leave a gap or opening 48 along the length of the panel. The outer edges of the strips extend laterally beyond the edges of the sections 42. A diffusing plate 50 is inserted through the opening 48 and serves to diffuse the light from the fixture 52.

The panels are joined together side by side of an interlapping joint 54 and may be joined together in any desired relationship, such as for example an alternate arrangement of sound absorbing and lighting panels, or if desired a plurality of sound absorbing panels may be interposed between adjacent illuminating panels. When thus assembled there is provided a channeled or fluted assembly having elongated, parallel, alternated upwardly open and downwardly open channels.

The panels are initially provided and interconnected 'so as to provide a form or mold for pouring concrete. To retain the panels rigidly assembled in place prior to pouring and to effect a permanent secure interlock between the panels and concrete, the metal strip 56 is provided. The strip is rigidly secured to the panels by welding as at 57.

The side walls 58 of the sections and the side walls 59 of the sections 42 of the panels 40 define therebetween upwardly open channels designated at 60. The ends of the channels 60 are open for a purpose which will presently appear.

To extend the channels 60 upwardly beyond the side walls 58 and 59 and thus to deepen the channels, the filler forms 62 are provided. The forms are rectangularly shaped box-like elements having an open bottom side. They may conveniently be fabricated of a fireproof, waterproof, coated, corrugated cardboard material by die cutting the board to be folded and allowing extensions 64 and 66 of the two long sides 68 to fold over and form the short end, and the extension 70 of the top to fold around the portions 64 and 66 to provide a friction lock between the inner surfaces of the sides 68, as best seen in Figure 2. The two long sides are extended at 72 beyond the short end and have cut-outs at 74 to provide clearance 22 of the panels 20 for'the'strips'56; A'n eggcrate like "element 76 fills the interior of the form to provide rigidity to keep the form from collapsing from external forces such as the weight of workmen, weight of the wet concrete before it sets, etc. The filler forms 62 can be shipped to the construction site in knocked down form and assembled on the job and fastened together as by stapling or friction look as previously described.

The forms are made in lengths convenient to facilitate shipping, assembly and handling, and after being assembled are placed on top of the metal panels with their ends abutting, the extensions 72 holding them against lateral movement, and the cutouts 74 engaging strips 56 to prevent longitudinal movement. If desirable, the cutouts 74 can be made by a sharp implement at thetime the forms are placed in position on the metal panels to facilitate alignment with the strips 56. The walls 68, 58 and 59 completely form the sides of the channel 69.

When concrete, designated generally at 80, is poured over the assembly of panels and filler forms the concrete flows into the channels 60 thereby forming integral depending concrete joists 82 depending from the underside of a smooth flat continuous concrete slab 84 with the joists 82 and the slab 84 being contiguous with and extending between main supporting beams 86 which may be formed by pouring concrete into the wood framing structure generally designated at 88. Rods 90 serve to reinforce the concrete structure. The open ends of channels 60 cause the ends of joists 82 to connect integrally into beams 86.

To help support the metal panels 20 and 40 while the concrete is being formed and before it hardens shoring 92 is spaced intermediate their ends. This also allows an optimum weight and size of panel to be used contributing to the economy of the structure.

When the distances spanned by the panels and the loads carried by the floor vary in different areas of the building structure, it is desirable to increase or decrease the depth of the joist formed by the channels 60 between the panels. To accomplish this a filler form 106, best illustrated in Figure 4, of a different height is used.

The forms 100 are similar to forms 62 and have the side walls 102 with the extension 104, and when placed on top of metal panels 20 and 40 the walls 102 form with walls 58 of panels 20 and walls 59 of panels 40 a channel 106. When filled with concrete and allowed to harden, a joist 108 of less depth than joist S2 is formed. Bars 110 are put in place before pouring to reinforce the concrete. When joists and distribution ribs of a different depth are required a filler form of the necessary height can be used to obtain the required joists and ribs.

When desired, distribution ribs running in a direction 90 degrees or laterally to the joists 82 or 108 can be formed. As best seen in Figure the ends of forms 62 or 100 can be spaced apart when placed on the metal panels 20 and 40 so that the end portions 80 form a channel 112 which when filled with concrete, forms the rib 114. A rod 116 reinforces the concrete. The lateral rib 114 is of a depth equal to the height of the forms 62.

It can readily be seen from the above description that a series of floor joists and lateral distribution ribs of various depths can be obtained in a building construction to suit conditions required by span and loading all with one size and weight of metal panels, all of which contribute to economy in erecting the building structure. The filler forms remain embedded in the concrete Where they are not exposed to any outside surfaces, and by being left inplace in the building structure do not necessitate any expense 'for removal. Their permanent existence does not in any manner affect the performance of the formed concrete or of the metal panels.

While reference has been'made to cardboard as a suitablematerial for the filler forms and reinforcing elements, it will be apparent that a molded material such as a suitable plastic or fibrous material, or'metal,"may be employed.

The drawings and the foregoing specification constitute a description of the improved system of building construction in such full, clear, concise and exact terms as to enable any person skilled in the art to practice the invention, the scope of which is indicated by the appended claims.

What I claim as my invention is:

1. Extension forms for increasing the depth of beams or joists of concrete in combination with panels including upwardly extending elongated continuous, downwardly open trough members defining upwardly open channels therebetween, said forms comprising hollow box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said trough members, said extension forms having end walls of less height than its side walls to rest upon the top of said trough members, said side walls overlapping the sides of said trough members to prevent lateral shifting thereon.

2. Extension forms for increasing the depth of beams or joists of concrete in combination with panels including upwardly extending elongated continuous, downwardly open trough members and interconnected by a tie member secured to the top surfaces thereof and defining upwardly open channels therebetween, said tie member extending across the tops of a plurality of trough members, having its ends secured to separated trough members and intermediate portions secured to the tops of trough members intermediate those to which its ends are secured, said forms comprising hollow box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said trough members, the side Walls of said extension forms having notches to receive said tie member and thereby prevent longitudinal shifting on said trough members.

3. Extension forms for increasing the depth of beams or joists of concrete in combination with panels including upwardly extending elongated continuous, downwardly open trough members and interconnected by a tie member secured to the top surfaces thereof and defining upwardly open channels therebetween, said forms comprising hollow box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said trough members, the side walls of said extension forms having notches to receive said tie member and thereby prevent longitudinal shifting on said trough members, said extension forms having end walls of less height than its side walls to rest upon the top of said trough members, said side walls overlapping the sides of said trough members to prevent lateral shifting thereon. I

4. Extension forms for increasing the depth of beams or joists of concrete in combination with panels including upwardly extending elongated continuous, downwardly open trough members defining upwardly open channels therebetween, said forms comprising hollow box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said trough members, said members being formed of a single sheet of material cut to form relatively wide side walls having narrower end extensions folded to extend across the ends of said member, and end walls folded over said end extensions and of a width to wedge between the side walls when folded within said box to abut the inner surfaces of said end extensions.

5. Apparatus for pouring a concrete floor-ceiling construction which comprises upwardly open channels shaped to form main supporting beams, elongated sheet metal panels having laterally extending horizontal flanges and elongated upwardly extending downwardly open troughs spaced inwardly from the edges of said flanges, said troughs extending the full length of said panels and defining therebetween upwardly open joist forming channels open at their ends into the beam forming channels, strips extending across the tops of said troughs to interconnect them and to form a permanent interlock with concrete when poured thereover, and downwardly open rectangular caps formed of light sheet material positioned over said troughs to extend them upwardly to deepen the joist forming channels, the side walls of said caps being of greater height than the end Walls thereof to extend downwardly and engage the sides of said troughs, the side walls of said caps having slots extending upwardly from the free edges thereof to receive said strips.

6. Extension forms for increasing the depth of beams or joists of concrete in combination with panels having upwardly extending elongated continuous downwardly open troughs spaced laterally from each other to define upwardly open channels therebetween, said forms comprising hollow elongated box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said troughs, each of said members being formed of a single sheet of material cut to form side wall portions having narrower end extensions folded to extend across the ends of said member, and a top wall portion having elongated end extensions folded over the end extensions of said side wall portions and into the interior of said member, the end extensions of said side and top wall portions forming a reinforcing multi-ply end Wall structure resting upon the upper surface of said trough.

7. Extension forms for increasing the depth of beams or joists of concrete in combination with panels having upwardly extending elongated continuous downwardly open troughs spaced laterally from each other to define upwardly open channels therebetween, said forms comprising hollow elongated box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said troughs, each of said members being formed of a single sheet of material cut to form relatively wide side wall portions having narrower end extensions folded to extend across the ends of said member, and a top wall portion having elongated end extensions folded over the end extensions of said side wall portions and into the interior of said member, the end extensions of said side and top wall portions forming a reinforcing multi-ply end wall structure resting upon the upper surface of said trough, the said end wall structure being of less height than the side walls of said member, said side walls extending below the top surface of said trough and engaging the sides thereof to locate said member laterally on said trough.

8. Extension forms for increasing the depth of beams or joists of concrete in combination with panels having upwardly extending elongated continuous downwardly open troughs spaced laterally from each other to define upwardly open channels therebetween, said forms comprising hollow elongated box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said troughs, each of said members being formed of a single sheet of material cut to form relatively wide side wall portions having narrower end extensions folded to extend across the ends of said member, and a top wall portion having elongated end extensions folded over the end extensions of said side wall portions and into the interior of said member, the end extensions of said side and top wall portions forming a reinforcing multi-ply end Wall structure resting upon the upper surface of said trough, the said end wall structure being of less height than the side walls of said member, said side walls extending below the top surface of said trough and engaging the sides thereof to locate said member laterally on said trough, reinforcing members extending across said channels and interconnecting adjacent troughs, and notches in the side walls of said box-like member receiving said reinforcing members and operating to locate said box-like members longitudinally on said troughs.

9. Extension forms for increasing the depth of beams or joists of concrete in combination with panels having upwardly extending elongated continuous downwardly open troughs spaced laterally from each other to define upwardly open channels therebetween, said forms comprising hollow elongated box-like members formed of light sheet material open at the bottom and shaped to fit over and extend upwardly from said troughs, the side walls of said members extending below the tops of said troughs to locate said members laterally on said troughs, the end walls of said member being shorter than said side walls and resting on the upper surfaces of said troughs, and egg-crate reinforcement disposed within said members and extending between the top surfaces of said troughs and the bottom surfaces of the top walls of said members at central zones remote from the ends thereof.

References Cited in the file of this patent UNITED STATES PATENTS 1,148,228 Higgins July 27, 1915 1,787,030 Andrews Dec. 30, 1930 1,892,311 Macdonald Dec. 27, 1932 2,022,622 Kahn Nov. 26, 1935 2,206,939 Carilli July 9, 1940 FOREIGN PATENTS 247,952 Great Britain of 1926 704,541 Great Britain of 1954 1,075,822 France of 1954 

